FEA Strength and Fatigue 6 years

4/2015 – 12/2018

Engine Subsystems Simulations Delivered:
· Cylinder-Head-Block: Thermomechanical strength and fatigue, Gasket evaluation, Bore distortion
· Main Bearing Wall: Strength and fatigue under gasload, Splitline evaulation, Minimum oilfilm thickness evaluation
· Cranktrain: Crankshaft 1D torsional - AVL excite, Crankshaft strength and fatigue, Crank pulley & flywheel strength
· Connecting rod: Strength and fatigue under gas load and inertia load, Splitline evaluation, Buckling, Shell back pressure
· Valve train: Camshaft strength and fatigue under camloads and chain loads, Push rod buckling, rocker arm strength
· Exhaust manifold: Thermomechanical analysis strength, Gasket performance · Intake & Exhaust system: Modal, Gravity load, FRF, Vibration fatigue
· FEAD system: FEAD and front cover strength and fatigue, power train bending.

Projects Delivered:
· 3 cylinder Gasoline Turbochanged engine and Naturally Aspirated engine for SUV
· 4 cylinder Diesel Turbochanged engine and Naturally Aspirated Engine for export tractor
· 1 cylinder Diesel Engine and 3 cylinder Diesel engine for Genset application
· 4 Cylinder high capacity Diesel engine for 3 tonn truck and 6 cylinder Diesel engine for Heavy truck

Software: Hyperworks, ABAQUS, AVL Excite, MSC NASTRAN, FEMFAT, Optistruct, MSC ADAMS, Ncode Glyphworks.
Types of Analysis: Cranktrain 1D torsional analysis, Linear and Nonlinear analysis, Contact based analysis, Nonlinear materials with elasto-plastic properties, Thermo-Mechanical strength analysis, Static, Modal, Buckling, Fatigue, Optimization, FRF, Vibration fatigue.
· Vast experience in failure investigation and optimized design solutions to meet project requirement.

Handling an entire gamut of activities related to CAE simulation: FEA model building for solvers such as Abaqus, AVL Excite, Nastran, Optistruct, FEMFAT Post-processing of analysis results to understand critical areas, load path and find feasible solutions Providing design modification suggestions based on FEA results, feasibility, manufacturability and cost Formulating detailed analysis and conclusion reports & presenting to Project team Conducting dynamic simulation using ADAMS and AVL Excite to extract loads for FEA analysis

CAE (rechnergestützte Entwicklung / computer-aided engineering)

8/2012 – 3/2015

Responsible for end to end delivery of FEA simulations, design modifications, failure investigation and new method development.

Software: Hyperworks, ABAQUS, AVL Excite, MSC NASTRAN, FEMFAT, Optistruct, MSC ADAMS, Ncode Glyphworks

Vehicle Subsystems Simulations Delivered:
· BIW: Accelerated Durability Test under road load condition - 321g, 2g twist, frontal impact, trimmed and untrimmed modal analysis, Bending & Torsion stiffness, floor sage, Tow hook strength and fatigue
· Closures: Side door and tail door torsional stiffness, door sage, door over open, oil canning, Dimpling, hood stay rod, hood re-enforcement strength and fatigue.
· Suspension System: Strength and fatigue analysis for LCA, twist beam, knuckle and K-Frame/Cross member
· Interior Trims: Strength, deflection, oil canning and Dimpling analysis for A-pillar, B-pillar, C-pillar trims. Strength, deflection and modal analysis for instrument panel.
· Exterior Trims: Strength, Deflection, Modal, and FRF analysis for Front bumper, Rear bumper and Rear view mirrors

Projects Delivered: Sub 4m SUV with monocoque body - KUV1OO for Indian and export market
Value Addition:
· Reducing 7 Kg weight from vehicle structure by Optistruct optimisation.
· Established methodology for tow hook FEA simulation.
· Achieved 90% correlation with test results for assembly level and component level simulation.

CAE (rechnergestützte Entwicklung / computer-aided engineering)